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Enameled Wrie

The enamelled resistance wires are coated with a dual coat modified polyester enamel system which combines the excellent physical and electrical properties of a modified polyester base coat with the added chemical resistance, surface toughness, smoothness and high thermal rating of a polyamide-imide polymer topcoat. The combination of these two high quality resins produces a coating that has outstanding abrasion resistance, flexibility, chemical resistance, burnout and thermal shock resistance and dielectric strength. These properties, coupled with careful selection and processing of the resistance wire, produces an enamelled wire which meets the exacting requirements of the automotive and electrofusion industry.
Availability:
Quantity:

Type of bare Alloy wire:
The alloy we can do enamelled are Copper-nickel alloy wire,Constantan wire, Manganin wire. Kama Wire, NiCr Alloy wire, PTC alloy wire etc alloy wire.
Size: Round wire:0.05mm~0.11mm 


Type of Insulation:

Insulation-enamelled Name

Thermal Level℃

(working time 2000h)

Code Name

GB Code

ANSI. TYPE

Polyurethane enamelled wire

130

UEW

QA

MW75C

Polyester enamelled wire

155

PEW

QZ

MW5C

Polyester-imide enamelled wire

180

EIW

QZY

MW30C

These enameled resistance wires have been broadly used for standard resistors, automobile parts, winding resistors, etc. using the insulation processing best suited for these applications,taking full advantage of the distinctive features of enamel coating.


Table 8  Types and Features of Enameled Coating of Resistance Wire

Name

Symbol

Temperature class
˚C

Feature

Polyvinyl fluoride

PVF

105

It has high flexibility, and the coating has excellent mechanical strength.
It has high durability during processing and high windability.
It has high chemical and solvent resistance.
Coating must be stripped before any soldering.

Polyurethane

UE

105

It has excellent workability, since soldering possible without stripping insulation.
Soldering at the temperature 380 ˚C is possible.
It has high chemical resistance.
It has high colorability, and wires in various colors are available.

Polyester

PE

155

It has high heat resistance, and is widely usable in various products.
It has high chemical and solvent resistance.
Caution required where used in airtight equipment, as it has low hydrolysis resistance.
Coating must be stripped before any soldering.

Table 10  Tolerance of insulation enameled resistance wire

Diameter
mm

Enameled resistance wire

min. Thickness of insulation
mm

max. Overall diameter
mm

0.050

0.004

0.069

0.060
0.070
0.080
0.090

0.004
0.004
0.005
0.005

0.081
0.091
0.103
0.113

0.100
0.110

0.005
0.005

0.125
0.135


Advantages of enamelled alloy wire

1.The enameled alloy resistance wire adopts the thermistor alloy wire with high positive resistance temperature coefficient. The characteristic of this alloy wire is that with the increase of heating temperature, the resistance increases rapidly, and the maximum temperature coefficient reaches 0.0039, which can realize the power saving ratio under different temperatures and effectively improve the safety of the heating pad. The power change curve is shown in the figure below.

2.The single wire diameter of enamelled resistance wire is usually designed to be less than 0.07mm, and the alloy wire is composed of multiple strands of resistance wire, so the tiny single wire diameter makes the power of alloy wire borne by each wire diameter less than 8%, and the safety performance is greatly improved.

3.Each alloy wire is insulated by the thickness of secondary paint film with temperature resistance of more than 180 degrees. The film adhesion is tested according to the national standard. The pressure resistance reaches 2700V, the number of pinholes is 0, the long-term aging resistance temperature of the paint insulation is 90 ℃, the short-term aging resistance temperature is 120 ℃, the low-temperature resistance is - 40 ℃, and the acid and alkali corrosion resistance.

4.When the enameled alloy wire is twisted, 400d Japanese Cola Li bullet proof wire is added. The bullet proof wire tension is greater than 100N, which ensures the tensile strength of the resistance wire. The winding structure makes the composite wire have a curvature around the bullet proof wire, effectively avoiding the longitudinal direct tension of the alloy wire when sewing the resistance wire.

5.The heating wires wound on the bullet proof wires are mutually enameled and insulated, so when the alloy wires are heated, they will not overheat and cause safety problems due to occasional broken wires, so the heating pad is more safe and reliable.

6. The heating pad made of the heating wire sewn on the non-woven fabric is selected as the seat heating wire by the BMW Benz car, which can effectively carry over 50000 bending tests of the robot.


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